Process Improvement at Automotive Assembly Line Using Line Balancing and Lean Manufacturing Approach

2020 ◽  
Vol 899 ◽  
pp. 268-274
Author(s):  
Mohamad Hafizdudin bin Tajul Arifin ◽  
Wan Emri Wan Abdul Rahman
Keyword(s):  
Process Improvement ◽  
Automotive Industry ◽  
Manufacturing Process ◽  
Production Line ◽  
Lean Manufacturing ◽  
Assembly Line ◽  
Line Balancing ◽  
Automotive Company ◽  
Automotive Assembly ◽  
Current Production

The aim of this study is to analyze the existing production line in the automotive industry and proposed a layout of improved production line in the manufacturing process and obtain the optimum rate of production time. Thus, line balancing method and Yamazumi Chart was utilized to analyze the current and proposed production line. The collection of the data of the existing production line was conducted at one of the automotive company in Malaysia. From the analysis of current production line, two improved layout were proposed and evaluated. The proposed layout was selected based on a balanced production line and ability to meet customer demand. A balanced production line will ensure smooth process and eliminate wastage during operation

STANDARDIZED WORK IN TPS PRODUCTION LINE

2015 ◽  
Vol 76 (6) ◽  
Author(s):  
Nurul Hayati Abdul Halim ◽  
Ahmed Jaffar ◽  
Noriah Yusof ◽  
Roseelena Jaafar ◽  
Ahmad Naufal Adnan ◽  
...  
Keyword(s):  
Continuous Improvement ◽  
Production System ◽  
Manufacturing Process ◽  
Production Line ◽  
Assembly Line ◽  
Process Stability ◽  
Automotive Assembly ◽  
Study Implementation

This paper presents a case study implementation of one of the Toyota Production System (TPS) tools, known as Standardized Work (SW), in an automotive assembly line in Malaysia. The main functions of SW are to design, develop, document and visualize a set of a manufacturing process with detail and proper study of it. SW is conducted to raise production consistency and quality of a produced product and the job performed. With the proper SW implementation, good results have been obtained from the increase in efficiency, productivity, quality and process stability of the operator’s performance. Thus, the findings are consistent with TPS philosophies which are waste elimination and continuous improvement in any manufacturing area.

Study on the Multi-Tag Identification Anti-Collision Algorithm of RFID in Automobile Assembly Line

2014 ◽  
Vol 687-691 ◽  
pp. 4056-4059
Author(s):  
Cheng Li Pang
Keyword(s):  
Automotive Industry ◽  
Assembly Line ◽  
Important Application ◽  
Identification System ◽  
Collision System ◽  
Tag Identification ◽  
Rfid Systems ◽  
Automobile Assembly ◽  
The Social ◽  
Automotive Assembly

With the mass production and use of car, the social are also increasing the requirements the automotive industry development. More and more automobile manufacturers are hoping to establish an efficient identification system, so that management would be enhanced to improve the efficiency and reduce the error rate. What’s more, motor-dom has been the important application field of RFID technique. In this paper, the paper is to carry out a detailed analysis of technology and research for RFID anti-collision system to guide manufacturers to improve the efficiency of RFID systems in the automotive assembly line and to solve the problem of collision multi-tag identification.

Study on Multi-Specification Small-Batch Line Balancing and Optimization Base on the Streamline Balancing

2014 ◽  
Vol 635-637 ◽  
pp. 1952-1955 ◽  
Author(s):  
Ji Jun Xiao ◽  
Shu Ou ◽  
Qing Hua Zhou ◽  
Hao Dong
Keyword(s):  
Production Line ◽  
Assembly Line ◽  
Mixed Model ◽  
Balance Method ◽  
Line Balancing ◽  
Workplace Design ◽  
Work Processes ◽  
Batch Production ◽  
Line Balance ◽  
Assembly Line Balance

Based on the principal concepts of streamline balance, this paper analyses the issue of the line balancing, through analyzing traditional assembly line balance method and having the bottleneck work processes to amend the parameters of the Workplace design, and then building up a multi-variety small-batch production line balancing mixed-model.

scholarly journals Two-Sided assembly line balancing to minimize number of workstation with considering the relationships between tasks

2018 ◽  
Vol 204 ◽  
pp. 02015
Author(s):  
Dina Rachmawaty ◽  
Putu Dana Karningsih ◽  
Budi Santosa
Keyword(s):  
Conceptual Model ◽  
Production Line ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Production Plan ◽  
Two Factors ◽  
Improvement Method ◽  
Increase Productivity ◽  
Assembly Line Balancing Problem

There are many problems in assembly line. Some of the problems are assembly line reliability which relates to maintenance and unbalance workload. As a result, production line is not efficient and production plan is not fulfilled. Previous research on two-sided assembly line balancing problem has proprosed improvement method by considering index relationship between tasks. There are only two factors that is taken into account in this research, they are: distance factor of the implementation of the task (distance factor) and tools used to perform the task (tool factor). Therefore, this paper aims to develops conceptual model by considering additional factors that affecting Assembly Line Tasks Consistency (ATC). The additional factors that are considered are as follow: distance factor, tool factor, motion factor, layout factor, and skill factor. The purpose of this conceptual model is to increase productivity by minimizing number of workstations. Linear combination are used to find a combination solution of a relationship between task to complete a two-sided assembly line balancing problem. Improvement of proposed assembly line are measured according to Balance Delay (BD) and Line Efficiency (LE).

Productivity Study and Line Balancing of GGMG & CALICO Production Line

2012 ◽  
Vol 576 ◽  
pp. 700-704 ◽  
Author(s):  
Hartini Mustafa ◽  
Ahmad Razlan Yusoff ◽  
M. Yusoff Ismail
Keyword(s):  
Cycle Time ◽  
Production Line ◽  
Assembly Line ◽  
Flow Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Buffer Allocation ◽  
Resource Assignment ◽  
Time Data ◽  
Current Case

Assembly line balancing is assumed to have fixed task within specified task time during the initial stage of the mass production. The problem of current case study of this assembly line was the production line cannot meet the expected output plan with imbalance station cycle time. In this paper, productivity study and line balancing is applied to improve production line of GGMG & CALICO. The desired cycle time defined using the Standard Time Data (STD) which required the person to perform assign task till completion by defining the performance rating of person. The proposed solution proved by the implementation analysis conducted in the research. The results showed that the productivity of production line which is tremendously increased within 50% after implementation. There are six factors identified during the study which are bottleneck stations, workpiece flow, line layout, ergonomic, resource assignment and buffer allocation.

scholarly journals Modular Home off-site Construction Production Line Improvement

2015 ◽  
pp. 503-512
Author(s):  
Youyi Zhang ◽  
Mana Moghadam ◽  
Mohamed Al-Hussein
Keyword(s):  
Production Line ◽  
Lean Manufacturing ◽  
Production Efficiency ◽  
Assembly Line ◽  
Modular Construction ◽  
Commercial Building ◽  
Market Competitiveness ◽  
Novel Approach ◽  
Building Information ◽  
High Production

Today modular and off-site construction practices are widely used as a novel approach to residential and commercial building construction. Although this approach is known for its high production efficiency and low material waste, manufacturers are facing the challenge of fully differentiating their modular construction procedures from the conventional construction approach. Manufacturers are thus seeking to continuously implement efficient methodologies to improve their production line effectiveness, thereby enhancing their market competitiveness. This paper proposes a methodology enabling the modular manufacturer to overcome this challenge and increase their assembly line productivity by implementing building information modelling (BIM)-supported lean manufacturing concepts, with a particular focus on the importance of the upstream pre-assembly line. This technique was implemented on a case-study, a residential modular factory, and increased the production line productivity by implementing the Lean-assembly concept. This approach is supported by the information provided from an enhanced BIM model generated to deliver accurate resource quantity required at each assembly station.

scholarly journals Line Balancing Analysis of Hollow Dakota 1730 Manufacturing Process in PT XYZ

2021 ◽  
Vol 328 ◽  
pp. 05012
Author(s):  
Rachmad Hidayat ◽  
Shofi fitrotis Salimah ◽  
Moh. Jufriyanto ◽  
M.Firman Khaqiqi
Keyword(s):  
Production Process ◽  
Manufacturing Process ◽  
Production Line ◽  
Idle Time ◽  
Line Balancing ◽  
Balance Performance ◽  
Production Lines ◽  
Work Station ◽  
Weight Method ◽  
Positional Weight

The existence of operational balance in each production lines may decrease the idle time; it shows that the productivity is increasing therefore it increases the production rate. The issues existed in the production process of hollow Dakota 1730 in PT. XYZ were 3 departments, from the result of the first observation, there was a bottleneck from each department and each production did not achieve the required target. Therefore, this research would fix the production line. The method used was ranked /positional weight. Based on the data processing by the ranked positional weight method, gained the total of work station in the production process of hollow Dakota 1730 by the number of 2 work stations. From the result of efficiency balancing, gained 62.5% and balance delay value was 37.5%. it shows that the balance performance between each department increases significantly.

scholarly journals A CASE STUDY ON IMPROVING THE PRODUCTIVITY USING IE TOOLS

2013 ◽  
pp. 249-252
Author(s):  
BHAVIK SHAILESHKUMAR SHETH ◽  
TANMAY SWAROOP ◽  
RABINDER HENRY
Keyword(s):  
Production Line ◽  
Assembly Line ◽  
Mixed Model ◽  
Assembly Line Balancing ◽  
Value Added ◽  
Work Load ◽  
Performance Measure ◽  
Line Balancing ◽  
Mixed Model Assembly Line ◽  
Mixed Model Assembly

Assembly line balancing has been a focus of interest in Industrial Engineering for the last few years. Assembly line balancing is the problem of assigning tasks to workstations by optimizing a performance measure while satisfying precedence relations between tasks and cycle time restrictions. Line balancing is an important feature in ensuring that a production line is efficient and producing at its optimum. The process of Line balancing attempts to equalize the work load on each workstation of the production line. Mixed model assembly lines are increasing in many industries to achieve the higher production rate. This study deals with mixed-model assembly line balancing and uses Yamazumi chart to break down the work element in to the value added & Non-value added part to reduce the waste & increase the productivity.

scholarly journals Lean Manufacturing Implementation through DMAIC Approach: A Case Study in the Automotive Industry

2021 ◽  
Vol 25 (2) ◽  
pp. 54-77
Author(s):  
Hanane Rifqi ◽  
Abdellah Zamma ◽  
Souad Ben Souda ◽  
Mohamed Hansali
Keyword(s):  
Automotive Industry ◽  
Lean Manufacturing ◽  
Added Value ◽  
Project Duration ◽  
Financial Gain ◽  
Automotive Company ◽  
Single Production ◽  
Lean Tools ◽  
The Right

Purpose: The main objective of this paper is to validate the results of the Lean manufacturing application via the DMAIC concept. This study concerns a case study carried out in an automotive company which aims at improving its flows within the production workshop by pulling the physical flow and minimizing the different wastes.   Methodology/Approach: By conducting a literature review to examine the different frameworks for applying the lean method and to extract case studies related to the DMAIC approach which is missing on the selected articles, only one article that addresses this possibility. Findings: DMAIC has allowed a better structuring of the entire project, choosing the right improvement solutions with the right choice of Lean tools and several advantages that are not valid for other frameworks. This implementation shows a spectacular improvement in the production planning, the fluidity of the flow as well as an important financial gain for the company. Research Limitation/Implication: The project duration was not sufficient to apply other beneficial lean tools as the study was limited only to a single production line. Originality/Value of paper: This article demonstrates the added value of the structured DMAIC approach to lean manufacturing methodology and implementation.

scholarly journals Assembly line balancing by using axiomatic design principles: An application from cooler manufacturing industry

2020 ◽  
Vol 8 (1) ◽  
pp. 31
Author(s):  
Ö. F. Yilmaz ◽  
Ö. F. Demirel ◽  
S. Zaim ◽  
S. Sevim
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Assembly Line ◽  
Design Method ◽  
Assembly Line Balancing ◽  
Axiomatic Design ◽  
Line Balancing ◽  
Maximum Output ◽  
Production Volume ◽  
Installed Capacity

<p>The philosophy of production without waste is the fundamental belief behind lean manufacturing that should be adopted by enterprises. One of the waste elimination methods is assembly line balancing for lean manufacturing, i.e. Yamazumi. The assembly line balancing is to assign tasks to the workstations by minimizing the number of workstations to the required values. There should be no workstation with the excessively high or low workload, and all workstations must ideally work with balanced workloads. Accordingly, in this study, the axiomatic design method is applied for assembly line balancing in order to achieve maximum output with the installed capacity. In order to achieve this aim, all improvement opportunities are defined and utilized as an output of the study. Computational results indicate that the proposed method is effective to reduce operators’ idle time by 12%, imbalance workload between workstations by 38%, and the total number of workers by 12%. As a result of these improvements, the production volume is increased by 23%.</p>

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